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ARCMASTER 401MST POWER SOURCE

Manual 0-5287

3-17

INSTALLATION, OPERATION AND SETUP

Graphic for SMAW (STICK)

Current

Welding current

ISt

Hot start current

Time

tSt

Hot start time

Art # A-12457

Figure 3-7 STICK Current Routing Diagram

ARCMASTER 401MST

Negative Welding

Terminal (-)

Work Lead

Electrode Holder

Positive Welding

Terminal (+)

Art # A-12551

Figure 3-8 Setup for STICK (SMAW) Welding

Summary of Contents for ARCMASTER 401MST

Page 1: ...Tweco com Art A 12449_AB ARCMASTER 401MST 3163339 Revision AB Issue Date June 17 2014 Manual No 0 5287 Operating Manual...

Page 2: ...stinguish ourselves from our competition through market leading innovation and truly dependable products that will stand the test of time We strive to enhance your productivity efficiency and welding...

Page 3: ...www victortechnologies com Copyright 2014 by Victor Technologies Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The pub...

Page 4: ...ser Responsibility 2 2 2 06 Transporting Methods 2 2 2 07 Packaged Items 2 2 2 08 Duty Cycle 2 3 2 09 Specifications 2 4 SECTION 3 INSTALLATION OPERATION AND SETUP 3 1 3 01 Environment 3 1 3 02 Locati...

Page 5: ...ing Problems 4 14 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Maintenance and Repair 5 1 5 02 Power Source Status Messages 5 2 5 03 Error Messages 5 2 5 04 Routine Inspec...

Page 6: ......

Page 7: ...dy 10 Ground the workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged par...

Page 8: ...sion of the American Welding Society AWS Miami Florida Guide for Shade Numbers Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No Comfort Shielded Metal Arc W...

Page 9: ...arc If this is not possible tightly cover them with approved covers 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 5 W...

Page 10: ...cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people re...

Page 11: ...e around the body 4 Keep welding Power Source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consul...

Page 12: ...e pressure regulation equipment Deviation from the following safety and operation instructions can result in fire explosion damage to equipment or injury to the operator E Compressed Gas Cylinders The...

Page 13: ...ing ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Was...

Page 14: ...ative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wi...

Page 15: ...NTRETIEN ET D ESSAI 1 06 Dangers relatifs au soudage l arc AVERTISSEMENT L ELECTROCUTION PEUT ETRE MORTELLE Une d charge lectrique peut tuer ou br ler gravement L lectrode et le circuit de soudage son...

Page 16: ...visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure AWS F2 2 2001 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Num...

Page 17: ...sse un pantalon revers des bottines de s curit et un casque 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 3 Entourez l aire de soudage de rideaux ou de cloisons pour...

Page 18: ...s et les pi ces connexes doivent tre maintenus en bon tat 6 Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf si...

Page 19: ...E LIQUIDE DE REFROID ISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression 1 N tez pas le bouchon de radiateu...

Page 20: ...Si vous ne pouvez pas les enlever prot gez les avec une cou vre ignifuge AVERTISSEMENT N effectuez JAMAIS d op rations de soudage sur un r cipient qui a contenu des liquides ou vapeurs toxiques combu...

Page 21: ...apublication CGAP 1 Manipulations curis edesgazcompri m s en conteneur pour plus d informations sur l utilisationetlamanutentiondesbouteilles AVIS Ce document CGA p t peut tre obtenu en crivant Compre...

Page 22: ...LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Comp...

Page 23: ...Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art A 07639_AB 115V 15A t t1 t2 X IPM MPM t Fusible D roulement du Fil Alime...

Page 24: ...ARCMASTER 401MST POWER SOURCE SAFETY INSTRUCTIONS AND WARNINGS 1 18 Manual 0 5287 This Page Intentionally Blank...

Page 25: ...back cover of this manual Include all equipment identification numbers as de scribed above along with a full description of the parts in error Move the equipment to the installation site before un cr...

Page 26: ...sary it is recommended that such repairs be carried out by appropriately qualified persons approved by Tweco Advice in this regard can be obtained by contacting an Accredited Tweco Distributor This eq...

Page 27: ...a 40 duty cycle 170 amperes at 26 8 volts This means that it has been designed and built to provide the rated amperage 170A for 4 minutes i e arc welding time out of every 10 minute period 40 of 10 m...

Page 28: ...460V 1 phase 26 6A 208V 3 phase 24 6A 230V 3 phase 14 3A 460V 3 phase Maximum Input Current I1max 84 7A 208V 1 phase 76 2A 230V 1 phase 40 1A 460V 1 phase 53 2A 208V 3 phase 49 1A 230V 3 phase 28 6A...

Page 29: ...e 3 Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your situation in this regard Note 4 Generator Requirements at the Maximum Output Du...

Page 30: ...ARCMASTER 401MST POWER SOURCE INTRODUCTION 2 6 Manual 0 5287 This Page Intentionally Blank...

Page 31: ...ronments with increased hazard of electric shock are 1 In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying...

Page 32: ...ectrical power from the welding power supply whenever necessary to inspect or service the unit NOTE This unit is equipped with a three conductor with earth power cable that is connected at the welding...

Page 33: ...the available input power Damage to the PCB could occur if 575VAC or higher is applied 3 05 High Frequency Introduction The importance of correct installation of high frequency welding equipment cann...

Page 34: ...of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the welding circuit see...

Page 35: ...s 3 Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level 4 Equipotential Bonding Bonding of all metallic...

Page 36: ...R 401MST POWER SOURCE INSTALLATION OPERATION AND SETUP 3 6 Manual 0 5287 3 08 ArcMaster 401MST Power Source Controls Indicators and Features 3 2 6 9 8 7 1 5 4 Art A 12452_AC 10 14 11 13 15 16 17 18 Fi...

Page 37: ...in 19 PIN Remote mode the 19 PIN control socket is active and remote voltage controls will be active Both 14 pin and 19 pin connectors work in all modes 3 Parameter Selection Button This button is use...

Page 38: ...1 to 10 press Parameter Selection Button Item 3 to load the job 7 Process Selection Button The process selection control is used to select the desired welding mode Six modes are available for the 401...

Page 39: ...and foreign material build up while providing optimum cooling Fan speed reduces approximately 30 seconds after machine is turned on and increases when internal components reaches operating temperature...

Page 40: ...nd common M 12VDC arc established 12 VDC while welding active otherwise off N Ground common P 24VAC R N VAC 24 115VAC neutral and chassis ground S CAN_high CAN bus positive signal T CAN_low CAN bus ne...

Page 41: ...ol Contactor Control Contactor operates in MIG TIG and Stick modes When the local Control LED is illuminated the output is enabled and when the Remote Control is illuminated the output is enabled by a...

Page 42: ...tter NOTE As the INDUCTANCE is increased the WELD V may need to be adjusted to achieve the desired weld characteristic HOT START This parameter operates in Stick and TIG modes Hot start can subtract 5...

Page 43: ...e Too little or too much arc force makes this process unstable The operator must adjust the arc force until a happy medium is reached ii Vertical up welding When welding vertical up with arc force on...

Page 44: ...upright position by chaining it to a suitable stationary support to prevent falling or tipping D Ensure that the gas cylinder is secured to a building pillar wall bracket or otherwise securely fixed i...

Page 45: ...Current I1 Welding current ISt Hot start current Iz Short circuit t Time tSt Hot start Art A 12456 Figure 3 5 TIG Current Routing Diagram ARCMASTER 401MST Negative Welding Terminal Work Lead Positive...

Page 46: ...hat the male plug is inserted and turned securely to achieve a sound electrical connection WARNING The polarity of the electrode depends on the type of electrode and the welding process Please follow...

Page 47: ...or SMAW STICK I Current I1 Welding current ISt Hot start current t Time tSt Hot start time Art A 12457 Figure 3 7 STICK Current Routing Diagram ARCMASTER 401MST Negative Welding Terminal Work Lead Ele...

Page 48: ...the male plug being fused in the terminal WARNING Before connecting the work clamp to the work piece make sure the mains power supply is switched off Secure the welding grade shielding gas cylinder i...

Page 49: ...19 INSTALLATION OPERATION AND SETUP Art A 12552 Positive Welding Terminal Wirefeeder ARCMASTER 401MST Tweco No 4 MIG Torch Work Lead 19 Pin Control Socket Negative Welding Terminal Figure 3 9 Setup fo...

Page 50: ...urce B Connect the work lead to the positive welding terminal If in doubt consult the electrode wire manufacturer Welding current flows from the Power Source via dinse type connectors It is essential...

Page 51: ...ned securely to achieve a sound electrical connection B Connect the control cable from the Wirefeeder to the 14 PIN or 19 PIN socket on the Power Source as applicable WARNING Before connecting the wor...

Page 52: ...st The test will last for about 5 seconds During the test all LEDs are lit Enable Calibration in MIG Mode In MIG mode the adjustment to output voltage can be enabled or disabled as below 1 Press Conta...

Page 53: ...the flowmeter regulator from a cylinder without first closing the cylinder valve and releasing gas in the flowmeter regulator high and low pressure chambers 4 DO NOT use the flowmeter regulator as a...

Page 54: ...r gas or gases to a cylinder containing any other gas 3 Connect the flowmeter regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively with a suitable spanner 4 Con...

Page 55: ...by opening the downstream valve Bleed welding grade shielding gas into a well ventilated area and away from any ignition source Turn adjusting screw counter clockwise until the required flow rate is i...

Page 56: ...ARCMASTER 401MST POWER SOURCE INSTALLATION OPERATION AND SETUP 3 26 Manual 0 5287 This Page Intentionally Blank...

Page 57: ...table precautions are not taken the occurrence in this zone of under bead cracks may result Hardened zone and under bead cracks in the weld area may be reduced by using the correct electrodes preheati...

Page 58: ...des dealt with in this publication can be used in most positions i e they are suitable for welding in flat horizontal vertical and overhead positions Numerous applications call for welds to be made in...

Page 59: ...16 to 4 8mm 3 16 depending on plate thickness Joint Open Square Butt 1 6mm 1 16 max 1 6mm 1 16 Single Vee Butt Joint Not less than 70 Double Vee Butt Joint 1 6mm 1 16 Lap Joint Tee Joints Fillet both...

Page 60: ...s freezing on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck As soon as the arc is established maintain an imperial dimensions 1 16...

Page 61: ...Weld Art A 07698 Figure 4 12 Weld Build up Sequence Heavy plate will require several runs to complete the joint After completing the first run chip the slag out and clean the weld with a wire brush I...

Page 62: ...and strike the arc in the corner of the fillet The electrode needs to be about 10 from the horizontal to enable a good bead to be deposited Refer Figure 4 15 Use a short arc and do not attempt to weav...

Page 63: ...ause of Distortion Distortion is caused by A Contraction of Weld Metal Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature This means that a cube of molten metal wo...

Page 64: ...g a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out See Figures 4 20 through 4 23 for various weld sequences Choice of a suitable weld sequence...

Page 65: ...C Figure 4 22 Reduction of Distortion by Preheating Art A 07709 Figure 4 23 Examples of Distortion Art A 07710_AB 1 Block Sequence The spaces between the welds are filled in when the welds are cool 2...

Page 66: ...Non metallic particles may be trapped in undercut from previous bead A If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode B Joint preparation too restric...

Page 67: ...etal or edge of the joint A Small electrodes used on heavy cold plate A Use larger electrodes and preheat the plate B Welding current is too low B Increase welding current C Wrong electrode angle C Ad...

Page 68: ...Gas as it is commonly referred to is a welding process in which fusion is produced by an electric arc that is established between a single tungsten non consumable electrode and the work piece Shieldi...

Page 69: ...stainless steel and copper Excellent arc starting Long life High current carrying capacity Red Zirconated 1 High quality AC welding of aluminium magnesium and their alloys Self cleaning Long life Mai...

Page 70: ...res operator competency While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operati...

Page 71: ...act with work piece or filler rod material A Clean the electrode by grinding off the contaminates B Work piece surface has foreign material on it B Clean surface C Gas contaminated with air C Check ga...

Page 72: ...ARCMASTER 401MST POWER SOURCE This Page Intentionally Blank BASIC WELDING GUIDE 4 16 Manual 0 5287...

Page 73: ...ut special equipment or knowledge Refer also to section 4 for solving welding problems The machine requires a minimum of care and maintenance Only a few items need to be checked to ensure trouble free...

Page 74: ...rvice Provider Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling An error code is displayed in the digital displays in the event of a malfunction You can switch ov...

Page 75: ...o Service Center for repair E18 Overload Protection Safety switch device to protect elec trical components Take to an accredited Tweco Service Center for repair E22 Mains Undervoltage Mains voltage on...

Page 76: ...ure that 1 Flexible cord is of the multi core tough rubber or plastic sheathed type of adequate rating correctly connected and in good condition 2 Welding terminals are in suitable condition and are s...

Page 77: ...39 38 44 19 18 7 16 9 10 24 33 12 11 32 43 8 Art A 12459 Figure 6 1 ArcMaster 401MST Spare Parts ArcMaster 401MST Spare Parts Item Description Des Ref Quantity Part Number 1 Side Panel Left 1 W7006700...

Page 78: ...Transformer T1 1 W7006727 29 ON OFF Switch SW1 1 W7006728 30 Bridge Rectifier BR1 1 W7006729 31 Input Mains Cable 1 W7006730 32 14 pin Remote Socket with Harness 1 W7006731 33 Insulating Bush 1 W7006...

Page 79: ...4 3 X10 1 X10 2 M2 M A4 DRV02 X7 1 X7 2 X7 3 X7 6 X7 4 X7 5 X7 7 X7 8 X7 9 X7 10 X6 1 X6 2 X6 3 X6 4 X6 6 X6 7 X6 8 X6 5 X2 3 X5 8 X5 6 X2 2 X7 1 X7 2 11 12 13 14 X6 9 X6 10 X6 11 X6 12 X5 3 X5 4 LP1...

Page 80: ...ARCMASTER 401MST POWER SOURCE APPENDIX A 2 Manual 0 5287 This Page Intentionally Blank...

Page 81: ...AL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTER RUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of Tweco with respect to any contract or an...

Page 82: ...This Page Intentionally Blank...

Page 83: ...ts No Labor Victor Professional Victor Technologies limited warranty shall not apply to Consumable Parts for MIG TIG Plasma welding Plasma cutting and Oxy fuel torches O rings fuses filters or other p...

Page 84: ...800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 6...

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